Fabricated ceiling construction



Oct. 17, 1961 J. T. CHOPPA 3,004,639

FABRICATED CEILING CONSTRUCTION Filed Dec. 10, 1959 2 Sheets-Sheet 1 m... c/OHN TCHOPPA 5 INVENTOR 1 BY /7 I I ATTORNEYS Oct. 17, 1961 J. T. CHOPPA 3,004,639

FABRICATED CEILING CONSTRUCTION Filed Dec. 10, 1959 2 Sheets-Sheet 2 Jab N7: CHOP/DA INVENTOR I BY 7 I I I ATTORNEYS United States Patent ()fiice 3,004,639 Patented Oct. 17, 1961 3,004,639 FABRICATED CEILING "corqsTnUcTroN John T. Choppa, 34 Shelter Sh, NewHaven',' Conn.

Filed Dec. 10, 1959, Ser. No. 858,315

Claims; (Cl. 189- 36) This invention relates to a ceiling construction, more particularly to interlocking frame elements for supporting an auxiliary or false ceiling below the main ceiling. The auxiliary ceiling may be of translucent material and lights placed between the main and auxiliary ceilings. Also, the space between the main and auxiliary ceilings may be used for air conditioning or heating.

The object of the present invention is to provide a novel joint for interlocking frame members supporting an auxiliary ceiling.

Another object of the present invention is to provide a novel joint which may be formed in existing structural members for supporting an auxiliary ceiling.

An additional object of the present invention is to provide a novel joint between structural members for supporting an auxiliary ceiling which facilitates the erection of the auxiliary ceiling by workmen of only ordinary skill and with few tools.

Still other objects, advantages and improvements will become apparent from the following specification, taken in connection with the accompanying drawings in which:

FIGURE 1 is an isometric view showing one of the structural members with part of the joint for an intersection formed thereon.

FIG. 2 is an isometric view showing one of the structural members with a part of the joint for a wall end support formed thereon.

FIG. 3 is an isometric view showing one of the structural members with a complementary part of the joint for the wall end support formed thereon.

FIG. 4 is a side elevational view showing another of the structural members with a different form of the complementary part of the joint for an intersection formed thereon.

FIG. 5 is a side elevational view showing in inverted position still another of the structural members with a further modification of the complementary part of the joint for an intersection formed thereon.

FIG. 6 is a top plan view of the structural member shown in FIG. 4.

FIG. 7 is a top plan view of the structural member shown in FIG. 5.

FIG. 8 is a top plan view, partly in section, taken on the line 88 of FIG. 9 and looking in the direction of the arrows, and showing the joint at an intersection between two of the structural members positioned at right angles.

FIG. 9 is a vertical sectional view, taken on the section line 99 of FIG. 8 and looking in the direction of the arrows, and further showing the joint at an intersection between two of the structural members positioned at right angles.

FIG. 10 is a vertical sectional view, taken on the section line 10-10 of FIG. 9 and looking in the direction of the arrows, and still further showing the joint at an intersection between two of the structural members positioned at right angles.

FIG. 11 is a side elevational view, showing one of the structural wall end members according to FIG. 2, but taken from the opposite side, and showing the completed joint between one of the transversely positioned structural members and one of the wall end members.

FIG. 12 is a top plan view, partly in section taken on the section line 1212 of FIG. 11 and looking in the direction of the arrows, and further showing the comstructural members and one of the wall end members.

FIG. 13 is a vertical sectional view, taken on the section line 13-13 of FIG. 12 and looking in the direction of the arrows, and still further showing the completed joint between one of the transversely positioned structural members and one of the wall end members.

FIG. 14 is an under plan view of the junction between a longitudinally positioned structural member and two aligned transversely positioned structural members, show ing a diamond shaped plate over the joint between the members.

FIG. 15 is a vertical sectional view, taken on the sec tion line 15-15 of FIG. 14 and looking in the direction of the arrows, and showing the attachment means for the diamond shaped plate to the flanges of the transversely positioned structural members.

Referring now to the drawings in detail, and to FIG. 1 in particular, one of the transversely positioned structural members is shown here. It is preferably made of aluminum and is comprised by a central web 10. and oppositely extending bottom flanges 1111. At its top the web is thickened at 12.

A hole 13 is formfld through the web 10 just below the thickened portion 12, this hole having a dual function, as will be later described. From the hole 1 a vertical slot 14 extends downwardly and has a bottom 15, which is positioned a short distance above the flanges 11 11. At one side of the slot 14 there is formed an auxiliary 9 comp s d y a horizontal, p tio 1 d' rtical portion 17, the portions of the web between the slots 14 and 17 forming a tongue 18, The tongue 18 is undercut to form a ledge at 19.

The hole 13 provides a starting point from which the lot and 6+1 m y e fq m Both lots may be, of se w b ha d by th us o a co wa mass production basis, however, the slot 14 may be formed on a milling machine, this slot being, of course, a t h way e P rt al c rv l t 16-4 may also be formed on a milling machine by having the work piece pattern controlled. i

In FIG. 2 there is shown one of the structural wall end members. These are also preferably made of aluminum and are comprised by vertically positioned flanges 20.az 1 d outwardly extending horizontal bottom flanges 21. At spaced intervals along its length the verticallyposi: tioned flange 20 of each wall 'end member is outstruck along a rectangular area 22, the metal being severed along the sides of the rectangle, but remaining united along the ends of the latter, and the, bottom of the rectangle being approximately flush with the top, of the bot: tom flange 21. At the mid-section of. the top of the rectangle there. is provided a cut-out section or notch 23, which has a dual function, to be later described. Along its vertical center line the outstruck portion 22 is formed with a vertically positioned slot 25 which is undercut at 25 has an end wall 2 6. At one side of the vertical center line the outstruck portion 2 is" provided with a vertically positioned notch 27, the material of the flange. between the slot 24 and the notch ZZ'fOrrning a tongue 28. The tongue 28 co-operates with a lug. 29 on the opposite side of the slot 2%. The cut-out section or notch 23 in the web 20 provides part of the material for the tongue 28 and the lug 29. i

In FIG. 3 there is shown one of the structural members 30 to be positioned at right angles to the structural members 10 of FIG. '1. These latter structural members are likewise made of aluminum. Each member is straight line section to form a tongue 32. A vertically positioned slot 33 is formed in the tongue 32 adjacent one end of the latter. Below the tongue 32 the side flagges 31-31 are cut away to form a forward edge a A first form of the part joint between the structural members 10 and the structural members 20, to be positioned at right angles thereto, is shown in FIGS. 4 and 6. A notch 3-5 is formed in the web of the member 30, extending from the bottom upwardly. Below the notch 35 the side flanges 31-31 are cut away to form a forward edge at 36. Above the notch 35 the web of the member 30 is formed as a triangular tongue 37. Adjacent the tongue 37 there is formed a slot 38 extending from the top of the web downwardly.

It will be understood, of course, that a complementary part joint would have the notch 35 and the tongue 37 interchanged in positions and the slot 38 would extend from the bottom of the web upwardly.

In the modification according to FIGS. 5-7, 8, 9, and 10, it being understood that the structural member 30a is shown in inverted position in FIGS. 5 and 7, the part joint is formed as upper convex tongue 39 and a lower concave notch 40, both the tongue and the notch being arcs of circles and the two arcs merging along the longitudinal center line of the web of the member 30. The slot 38 is formed in the web of the member 30a in the same relative position with respect to the tongue 39 as the slot 38 occupies with respect to the tongue 37 in the modification of FIGS. 4-6.

In use the structural members are positioned under the ceiling A (FIG. 10) in parallel relationship in one direction, either longitudinally or transversely of the room, as may be desired. They are supported along their lengths by hooks (not shown) from the main ceiling A, the hooks projecting into the holes 13 in the web 10. At their ends they may be secured to the walls in any suitable manner, for instance in the same manner as the structural members 30, 30a to be now described.

The wall end members are secured to the walls in parallel relationship to the structural members 10 and at a predetermined distance below the main ceiling A, at approximately the same height as the structural members 10, by nails or screws driven through suitable holes (not shown) in the vertically positioned flanges 20 and into the studding of the walls.

The structural members 30 are secured to the end wall members 20 by having their tongues 32 received in the slots 24 in the outstruck portions 22 of the latter. The cut out sections or notches 23 in the web provide clearance when the tongue 32 is inserted in the slot 24. The notch 33 in the bottom of the lug receives the end'wall 26 of the slot 24, as shown in FIGS. 11 and 13. In the stated position, the side flanges 31-31 on the transversely positioned structural members 30 abut the outer edge of the flange 21 on the wall end member 20 along the cutaway edge 34 of the former.

In like manner, the tongue 37 (FIG. 4), or the tongue 39 (FIGS. 5 and 10), is insented in the slot 14 in the web of the longitudinally positioned structural member 10. Complementary transversely positioned structural members 30 will generally be positioned in alignment with the first structural members 30. As before, in the stated position, the side flanges 31-31 on the transversely positioned structural members 30 abut the outer edges of the opposite side flanges 11-11 on the longitudinally positioned structural members 10 along the cutaway edges 36 of the former. The tongue 28 on the outstruck portion 22 of the web 20 on the end wall member is then peened over the top of the tongue 32 on the transversely positioned structural member 30 and against the lug 29 on the outstruck portion 22 of the flange 20 on the end wall member by being struck by a hammer through a blunt tool, such as a hand punch. Likewise, the tongue 18 on the web of the longitudinally positioned structural member 10 is peened over the tongue 37 (FIG. 4), or the top tongue 39 (FIGS. 5 and 10), of the transversely positioned structural member 30, in the same manner. The notch 38 in the tongue 37, or 38a in the tongue 39, refeives the tongue 18 above the undercut section 19 of the atter.

In FIGS. 14 and 15 the joint between the longitudinally positioned structural member '10 and the two aligned oppositely extending structural members 30-30 is covered on the under side by a plate having a diamond shaped center section 41. This plate is stamped from a square of heavy metal foil along lines joining the midsections of the square, being depressed from the bottom to form the raised diamond shaped center section 41. The diamond is further stamped with lines parallel to the sides and extending between the mid-points of the latter and also with diagonal lines, to enhance the decorative eflect. The corners of the original square blank are cut away along linesextending from the mid-points of the sides of the diamond and at 45 wit-h respect to the latter to form arms 42. One pair of oppositely extending arms 42-42 is of the same width as the overall width of the bottom flanges 11-11 on the longitudinally positioned structural members 10, and the other pair of arms 42-42 is of the same width as the overall width of the bottom flanges 31-31 on the oppositely disposed and transversely extending structural members 3030. In stamping one of the square blanks and forming the central diamond 41 and the arms 42 thereon, fingers 43-43 are formed at the end of each arm and on the opposite sides of the latter. These fingers are of generally rectangular shape and are co-incident at one end with the ends of the arms and along one side are integral with the latter. The diamond shaped center section of the plate 41 is centered with respect to the joint between the longitudinally extend-ing structural member 10 and the oppositely disposed and transversely extending structural member 3030 and the fingers 43 on the arms 42 are bent around the flanges 11-11 and 31-31 on the structural members 10 and 30-36, respectively. The arms 42-42 strengthen and tighten the joint between the longitudinally positioned structural members 10 and oppositely disposed and transversely extending structural members 30-39 and the diamond 41 provides a more ornamental appearance.

It will be understood that squares, or rectangles, of translucent glass (not shown) may be supported by the flanges 11 on the longitudinally positioned structural members 10 and the flanges 31 on the oppositely disposed and transversely positioned structural members 30-30 to form the translucent false ceiling and provide for the diffusion of the rays from lights positioned between the auxiliary or false ceiling and the main ceiling. Alternatively, squares or rectangles, of pargeting (also not shown) may be supported by the flanges 11 on the longitudinally positioned structural members 10 and the flanges 31 on the oppositely disposed and transversely positioned structural members 30 to form the auxiliary or false ceiling.

Having now fully described my invention, what I claim as new and useful and desire to secure by Letters Patent of the United States is:

1. A joint for structural elements including a first structural element having a web, wall portions of said web defining adjacent slots and an integral deformable tongue member between said slots, a second structural element disposed at right angles to said first element and having a longitudinally extending web, said web extending through one of said slots in the first element, portions of the -web of said second element defining a notch adapted to receive a portion of said deformable tongue.

2. A joint as defined in claim 1 which further includes a third structural element disposed at right angles to said first structural element on the opposite side from and in longitudinal alignment with said second structural element, said third element including a longitudinal web extending through the same slot in said first element as the longitudinal web of saidsecond element and in vertically and longitudinally aligned abutting engagement therewith.

3. A joint as defined in claim 2 wherein said third structural element includes wall portions defining a notch, the parallel wall portions of said notch engaging the web of said first structural element on opposite sides thereof.

4. A joint for structural elements including a first structural element having a web, wall portions of said web defining a pair of adjacent substantially parallel slots, an integral deformable tongue between said slots having an undercut area adjacent one end, second and third structural elements on opposite sides of said first element in longitudinal alignment with each other and at right angles to said first element, said second element having a longitudinal web extending through one of said slots in the web of said first element, wall portions of the longitudinal web of said second element defining a notch to receive a portion of said deformable tongue above the undercut area therein, said third element having a longitudinal web extending through the same slot in said first element as the web of said second element, the web of said third element in vertical and longitudinal aligned abutting relation with the web of said second element, wall portions of said third element defining a notch therein, the walls of said notch engaging the web of said first element on opposite sides thereof.

5. A joint for structural elements including a first structural element having a web, a portion of said web displaced from the planar face thereof, the intermediate area of said displaced portion in substantially parallel relation to said web, wall portions of said displaced portion of said web defining substantially parallel adjacent slots, an integral deformable tongue between said slots having an undercut area adjacent one end, a second structural element at right angles to said first element, said second element including a web extending longitudinally through one of the slots in the displaced portion of said first element adjacent the deformable tongue and being of a dimension less than the dimension of said slot, said tongue being deformed over said web, said Web further including wall portions defining a notch and engaging opposite sides of said displaced portion of the web in said first element.

References Cited in the file of this patent UNITED STATES PATENTS 1,346,426 Scherbner July 13, 1920 2,830,683 Griflith Apr. 15, 1958 2,873,828 Zitorner Feb. 17, 1959 FOREIGN PATENTS 798,488 France Mar. 10, 1936 

